Method of and apparatus for pouring concrete walls and floors of steel and concrete frame buildings



Feb. 5, 1929.

W. E. KELLER III'HOD OF AND APPARATUS FOR POURIIG 0011611813 IALLS AND FLOORS OF STEEL AND CONCRETE PRAIB BUILDINGS Film; llay 9, 1927 7 Shoots-Shoat 1 m" 4 Z a w r z ll" a H 3 y j v y a, 7 m 1 2 w a I 1 u n F 2 2 a 2 A w W a n/ m :7, Z 1 .Z f 5 1 0 0 o x n s sm n r r M J 2 M 1 Feb. 5, 1929.

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' W. E. KELLER IB'I'HOD OF AND APPARATUS FOR POURING CONCRETE WALLS AND FLOORS OF STEEL AND CONCRETE FRAME BUILDINGS Filed May 9. 1927 sheets-shed 3 Feb. 5, 1929.

w. E. kELLER IBTHOD OF AND APPARATUS FOR POURING CONCRETE IALLS AND FLOORS OF STEEL AND CONCRETE PM BUILDINGS Filed May 9, 1927 7 Sheeta Sheot 4 E I I "119;!627251572724072 0 a 7 2 Y Q w y u a x T 5 4 m z NWT; iw 2 6/ 1 w 0 7 1 L. I v w M 2 1. n4 6 y fl, 2 s M y 1 x 2 m 1 loao'a'oono "Feb. 5, 1929.

1 W. E. KELLER ammo!) or- AND APPARATUS FOR POURING coucnsu IALLs AND FLOORS OF STEEL AND CONCRETE FRAME BUILDINGS 1 Filed May 9, 1927 7 Sheets-Sheet 5 Feb. 5,1929." 1,701,113

' W E. KELLER IBTHOD OP'AND APPARATUS EPR POURING' CONCRETE 'ALLS AND FLOORS Q! STEEL AND CONCRETE FRAIB BUILDINGS Filed lay 9, 1927 'r Sheets-Sheet 6 Patented Feb. 5, 1929.

UNITED STATES PATENT OFFICE.

WILL E. KELLER, OF LOS ANGELES, CALIFORNIA.

MFITHOD OF AND APPARATUS FOR POURIN G CONCRETE WALLS AND FLOORS OF STEEL AND CONCRETE FRAME BUILDINGS.

Application filed May 9, 1927. Serial No. 189,840.

This invention pertains more specifically to concrete mold forms especially adapted for use in connection with steel frame or concrete buildings.

A chief Object of the present invention is to provide a novel set of mold forms that may be conveniently utilized in pouring the walls, floor beams, floor slabs and columns of a steel or concrete frame building structure, a story ata time, beginning at the uppermost floor and lowering the forms to pour the successive stories without the necessity of completely dismantling the forms.

Another object is to provide mold forms for steel and concrete frame building structures that may be used again on other similar building structures, thus effecting economy of operation and expense of construction.

Aiurther object is to provide a simple mechanism for lowering the mold forms after a floor pouring operation.

A still further object is to provide a construction whereby the size of the building supporting columns may be increased from time to time during the concrete pouring operation.

In pouring the concrete walls, floor beams,

floor slabs, and columns of steel and concrete frame buildings, it has lflsretofore been. the practice to erect mold forms around the steel or concrete frames beginning at the lowermost story or floor; and as each story is poured to dismantle the forms and again erect the same above the poured section. This method has not only proved expensive, but results in a loss of time and labor. By the use of the mold forms herein described economy of operation andexpense of construction is effected, as the walls, beams, columns, and floor slabs are poured from the uppermost story or floor, then moving the complete forms downwardly by means of suitable lowering apparatus a story at a time without totally dismantling the same.

Briefly, the invention herein set forth consists of providinga plurality of wooden concrete mold forms, for forming the outer Walls, beams, floors, and columns of steel frame building, or the floors of concrete structures. The forms are arranged and constructed in order that the building stories are poured successively from the uppermost, or an intermediate story downwardly to avoid the necessity of dismantling the forms as each story is poured as is the case when pouring the walls and floors from the lowermost story upwardly. Provision is made by means of cables,rods and the like for sus ending the forms in position for pouring, an means are also provided for lowering the forms a story at a time without the necessity of dismantling the forms other than to remove the form bottoms from the beam and wall molds in order to permit the passage of the forms past the floor beams of the story below.

In an embodiment of the invention herein described and illustrated in the accompanying drawings,

Fig. 1 is a sectional elevation of aportion of the upper story of a steel frame building with the mold forms in position for pouring concrete to form the roof, upper building walls, and the roof supporting columns.

Fig. 2 is a View similar to the above showing the upper story poured and the forms lowered to pour the adjacent story below.

Fig. 3 is a view similar to the foregoing Fig. 5 is a detail plan view of a floor section, illustrating the method of supporting the forms in position.

Fig. 6 is an enlarged plan view of the mold forms, partly broken away showing the floor deck, floor beams, wall molds, and supporting columns. i

Fig. 7 is an enlarged cross section of one of the outer wall forms taken on line 77 of Fig. 1

Fig. 8 is a detail longitudinal section through one of the wall mold forms taken on line 88 of Fig. 1.

Fig. 9 is an enlarged detail vertical section of one of the floor supporting columns.

Fig. 10 is a transverse section through one of the floor supporting columns taken on line 10 10 of Fig. 9.

Fig. 11 is a transverse section of the column form taken on line 11-11 of Fig. 9.

Fi 12 is a sectional elevation of a modified orm of mold form supporting and loW- drawings, 10 indicates a plurality of roofand floor mold forms, preferably constructed wood planking and joists securely nailed or bolted together, each pair being positioned between the horizontally disposed l[ beams 11 of the steel frame work -S.

Each form comprises a deck or platform 12 formed of planking 13 nailed to joists 14 that are in turn secured to cross beams 15, a pair for each deck term. Forms 10 are suspended in proper relation to the steel frame structure by means of a plurality of sectional steel rods 16 held together by couplings 18, the lower endsoi' the rods passing through the deck and joists 14k and ae secured to the cross beams by nuts 17. Some of the couplings 18 engage metal plates 19 which are disposed upon supporting frames generally designated at I each plate being pro vided with a slotted recess20 to permit oftv their removal from the rods when it is desired to lower the terms to pour the story below.

Supporting frame work -lpreferably consists of sills 21 that engage blocks re ing on the upper face of the -l'- beams ll and cross pieces 23 which support the metal plates 19. From the foregoing it will be seen that the floor forms are ultimately supported on the I beams ll oi the steel structure S- when they are in position. for pouring concrete. The floor tor-ms also term the sides of the beam terms generally designated at 24 and the upper end of the column forms. These beam forms consist of side walls which are carried by the floor forms 10 and extend downwardly from the deck to a point below the underside of the -I- beams 11.. The side walls 25 ot' the beam forms consist of horizontally disposed pieces 26 secured to the joists l4, and pieces 27 secured to the beams 18. Side walls 25 are slightly inclined and lined with a vertical facing adapted to permit an easy withdrawal from the hardened concrete when the forms are lowered, and the bottoms 29 of the beam forms are held in place by cleats 30 that are bolted as indicated at 31 to hangers 32 secured to the side walls 25 of adjacent decks. By means oi? the foregoing description it will be clear that the bottoms 29 may be readily removed :l'rom the forms to permit their passage past the cross beams of the steel frame when the forms are lowered.

The mold forms for forming the columns of the building are generally designated at 33 (see Figs. 9, 10, 11) and preferably consist of a plurality of vertically disposed mold walls 34 arranged in rectangular form, the upper ends of said walls lying flush with the upper faces of the bottoms 29 ot the beam forms 25 and communicating therewith, in order that the concrete when poured to form the floors and beams will flow downwardly into the column forms to encase the column beams. rest on wedges lO disposed on the -I- beams The lower ends of the column il'orn'r 11, and the bottoms of the column forms are removable in order when it becomes necessary to lower the forms after a floor molding operation the column forms may be readily removed to permit of a lowering of the floor and beam forms may be more fully described hereinafter. Column mold form bottoms consist of two wood plates 41 which are cut to lit in the channels of the vertical -I- beams 39 as indicated at 42, and two plates e3 which engage the sides oi the I- beams, all the plates resting on the wedges 40. The side walls of the forms are securely held together by bars a l which engage the same and are held in place thereon by bolts 45 that pass through holes 46, a number of these holes being provided in each bar Mr to permit of an enlargement of the column forms as the size of the columns are increased. The corners of the floor forms adjacent each vertical I beam column are cut away at right angles as at for the reception of a plurality of vertically disposed column mold walls 37.

By means of the above arrangement the cross sectional area of the columns may be readily increased on the succeeding low-er floors alter the tloor molds are lowered downwardly to the floor below.

The outer walls of the building structure are formed by wall mold forms generally designated at and comprise inner and outer parts 51 and 52 respectively which are held in spaced relation and form a moulding cavity adapted to receive concrete for forming the outer walls. The inner and outer parts 51 and 52 consist of a plurality 0i studs 53 upon which mold walls 5st are secured on the side adjacent the -I-- beams of the steel structure and are rdaintorced by struts 55, the upper ends 01" the inner parts being hinged or pivotally connected to the floor forms by eye bolts 56 extending through the upper struts and ei'igaging hooks 57 secured to the joists 14;. The outer part 52 of the wall mold forms is oil the same construction as the inner part 51 with the exception that their upper portions 59 extend above the level oi? the horizontal -I- beams in order to prevent concrete from running over the edge during a pouring operation. The inner and outer parts 51, 52 are held together and in spaced relation by a plurality of bolts 60 which pass through spacers 61 positioned between the walls of the parts 51 and 52.

Referring to Figs. 7 and 8, the bottoms of the wall mold forms consist of two side rails 62 between which are positioned a plurality of short pieces 64, in spaced relation, and the rails are provided with a plurality of notches 65 cut in their inner faces and serve to hold the reinforcing bars 66 in spaced relation. Gaps 67 between the ends of the pieces (i l are closed by thin metal plates 68 which have oppositely disposed notches 69 therein that coact with the notches 65 in the rails 62 in run-way 72 having a railing 73, so that the workman may stand thereon whileassembling the inner and outer parts of the wall mold forms.

The form supporting rods 16 pass through small tubes 7 resting on the deck 12 and serve to prevent concrete from coming in contact with the rodswhen the molds are poured, the

internal diameter of these tubes being large enough to allow the couplings 18 to pass therethrough when the forms are lowered.

. In forming the walls, columns and beams of the building concrete is poured on the deck of the floor form and evenly distributed thereon, the columns, beams and wall forms are filled and tamped in the usual manner, which results in forming the outer Walls, columns, beams and roof or floors of one story of the building in one operation.

The lowering of the forms is preferably done by means of chain blocks 80, having hooks 81 engaging eye bolts 82 screwed into the upper ends of the upper couplings 18 on the rod 16. As shown in Fig. 1 the chain blocks are suspended from frames 84 for the purpose of lowering the forms after the roof and uppermost floor is poured, the blocks then being supported on eye bolts 85 screwed in the couplings 18 which engage the plates 19 resting on timbers disposed on the set concrete roof as shown in Fig. 3. Before lowering the forms it:will become necessary to remove the bottoms of the beams, walls and column forms and the bolts 60 of the wall forms as well as to disassemble the column forms in order that the forms may readily pass the steel beams therebelow. The bottoms of the beam forms are released by removing the bolts 31 passing through the cleats 30 and hangers 32, and the bottoms of the column and wall forms are released by removing the wedges 40 and respectively.

It will be seen that after the bolts 60 of the outer wall forms are removed the outer parts 52 are entirely disconnected from the inner parts 51, and are suspended on cables 86 which are connected to the uppermost strut 55 and extend upwardly to and are connected to a suitable lowering mechanism (not shown).

In order to lower the forms, the couplings 18 are alternately unscrewed sufliciently to allow removal of the plates 19, and tightened again on the rods 16, the forms may then be lowered by the chain blocks until the next couplings engage the plates 19, it being understood that the plates 19 are returned to the rods after the first coupling has been moved down so that the plates 19 will function. as intended, to-wit: to support theforms as previously described.

If necessary the center of each floor slab may be supported by a rod 90, the upper ends of which extend through tubes 92 embedded in the floor above and are held in lace by nuts 93 engaging the plates 19. Tie lower ends of these rods extend through blocks 98 which carry a removable portion. 99 of the deck which remains under the floors after the forms are lowered as indicatedat 100 of Fig. 3.

As shown in Fig. 12, the floor forms are shown supported on shores or props 102 which engage wedges 104 resting on the I- beams 11. Cables 105 are shown forlowering the forms in place of the rods 16, and may be operated from a hoisting drum (not shown). a

In Fig. 13 a slightly modified form of rod 106 is shown in which hooks 108 and eyes 109 are employed in place of the couplings 18. Nuts 110 are threaded on the rods below the eyes 109 and are adapted to engage the plates 19 in a similar manner to the couplings 18.

It will be understood that while the mold form structure is particularly designed for pouring the walls, floors, and columns, of

steel frame buildings, yet it will be understood that the floor mold forms can be utilized for pouring the floor slabs of reinforced concrete framed building structures, the forms being lowered in the same manner as heretofore described.

What I claim is:

1. The herein described method of encasing the frame of a building structure with concrete which comprises suspending floor forms and portions of the inside wall forms from the uppermost or of an intermediate building floor, then pouring the concrete within the forms and allowing the same to set, and finally lowering the tourism 'sueceeding floors and proceeding as in the first instance.

2; The herein described method of encasing the frame work of an erected building structure with concrete, which consists of suspending a plurality of concrete. mold forms for forming the outer walls, floors, and columns of the structure from an up er story of the building, and then proceeding downwardly as the walls, floors and columns are poured to the base of the building,'a Story at a time.

3. A. concrete mold form for pouring the concrete walls, floors, and columns of an erected building structure com risin a plurality of mold forms connected movable as a unit, means to movably suspend the mold form from the building structure, and means comprising the suspending means together and to directly lower the floor and wall forms from an upper story to a lower one as the building frame work is encased in concrete.

4:. A concrete mold form for erected frame building structures comprising outer mold wall and floor forms connected together, means to support said forms from an upper floor of said building structure, and means to lower the forms into position for pouring succeeding floors and walls therebelow as each story is poured.

5. A concrete mold form for framed buildings comprising horizontally disposed concrete molds forforming the floors of said building structure, and means for lowering the forms into position for pouring succeeding floors therebelow after a floor is poured.

6. An apparatus of the class described comprising a plurality of concrete mold forms for pouring the walls and floors of building structures, cables for suspending the forms in position on the building structure, and chain blocks for lowering the forms in a downward direction directly and successsively asthe walls and floors are poured.

7. An apparatus of the class described comprising a plurality of vertically disposed wall concrete mold forms and a plurality of horizontally disposed mold forms connected together for forming the floors of a building structure, the molding cavities of said forms being inter-connected in order that the walls and floors may be monolithically formed, and means to lower the forms in a downward direction directly and successively as the walls and floors are poured.

8. An apparatus of the class described comprising a plurality of vertically disposed wall mold forms and a plurality of horizontally disposed floor and beam mold forms all secured together for forming the walls and floors of framed building structures, a plurality of colunm mold forms connected to the floor mold forms, said last named forms being detachably connected to the floor forms, the molding cavities of all the forms being interconnected, whereby the walls, floors, and columns may be poured simultaneously and monolithically, and means to lower the'forms in a downward direction directly and successively a story at a time as the pourmg of the bullding progresses.

9. An apparatus of the class described comprising a plurality of vertically disposed wall mold forms and a plurality of: horizontally disposed floor and beam mold forms, a plurality of independent column mold forms, the molding cavities of all the forms being connected, means to remove the bottoms of the wall, beam, and column mold forms when it is desired to lower the same, means to suspend said wall, beam, and floor forms, and means to lower the wall, beam, and floor forms as each story is poured.

10. An apparatus for pouring the walls, floors, columns, and beams oi: framed building structures comprising wall, floor, and beam molds, and a plurality of suspension rods connected to the floor and beam forms for suspending and lowering the forms successively from the uppermost to the lowermost building stories as the same are poured.

11. A molding apparatus for forming the walls, floors, beams, and columns of framed building structures comprising a plurality of wall, floor, and beam mold forms for encasing frame of said building structure, a story at a time, said forms being connected for pouring the walls, floors and beams simultaneously, cables for suspending the forms, and means to operate the cables to lowerthe forms alter a pouring operation.

12. An apparatus of the class described comprising a plurality of vertically disposed wall mold forms and a plurality of horizon tally disposed mold forms for forming the floors and beams of a framed building structure, a plurality of column mold forms for encasing the supporting columns of the building all the mold cavities being interconnected, whereby the walls, beams, floors and columns may be poured simultaneously and monolithioally a story at a time from an upper story downwardly, means connected with the column forms for increasing their cross sectional area as each successive building story is poured, and means to lower the wall, beam, and floor forms as each building story is poured. i

In witness that I claim the foregoing I have hereunto subscribed my name this 3rd day of May, 1927.

WVILL E. KELLER. 

